Wire Electrical Discharge Machine Corner Precision Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Wire electrical discharge machining faces challenges in achieving precise machining of arc corners due to wire electrode bending, leading to displacement and path length differences, resulting in excessive intake and residual at corner parts and exit parts, which affect machining precision.
Innovation Solution
A wire electrical discharge machine with a machining path compensation unit that calculates compensation vectors based on indicators such as wire electrode deflection, voltage change, movement speed, and electrical discharge pulse number to adjust the machining path, including inserting compensation blocks to improve corner part and exit part precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wire electrode is used for machining arc corners, then electrical discharge machining can be performed, but wire electrode bending causes displacement between command position and actual position
Solution Approach 1:
The system performs preliminary detection of wire electrode deflection before machining arc corners, calculates the actual wire shape in advance, and pre-compensates the machining path by adjusting the command positions. This preliminary action prevents the displacement error from occurring during actual machining, thereby improving arc corner machining precision without requiring physical wire electrode modification.
2Productivity
If wire electrode continuously supplies mechanism is used, then wire electrode consumption is compensated, but path length difference occurs between machining path and program path
Solution Approach 1:
The system continuously detects the actual wire electrode shape during machining and feeds this information back to the control unit. The control unit calculates the deviation between the actual wire position and the command position, then dynamically adjusts subsequent command positions to compensate for path length differences. This feedback mechanism maintains both continuous wire supply and path length accuracy.
3Manufacturing precision
If electrical discharge control is changed at corner parts, then excessive intake and residual can be reduced, but machining precision still cannot be fully improved
Solution Approach 1:
The system introduces an intermediate calculation step that determines the actual wire shape as a mediator between the simple program path and the complex discharge control. By calculating command positions based on the detected actual wire shape, the system creates an intermediate reference path that automatically compensates for deflection effects, achieving high precision without complex real-time discharge parameter adjustments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances machining precision of corner parts and exit parts by compensating for wire electrode bending and electrical discharge density variations, reducing residual and excessive intake, thereby improving the overall machining accuracy.
Implementation Method 1
performs electrical discharge machining on a workpiece (for example, the workpiece W described later) by making a wire electrode (for example, the wire electrode 5 described later) and the workpiece to relatively move according to the machining path
Data Source
AI summary
To provide a wire electrical discharge machine for which the machining precision of corner parts and corner exit parts in a workpiece are improved. A wire electrical discharge machine includes a machining path compensation unit which compensates a machining path, in a case of creating a corner part which is a circular arc as a second machining block, by compensating a position of a center of the circular arc of the second machining block by way of a first compensation vector calculated based on at least one indicator among the four indicators of deflection of a wire electrode, etc., and inserting a linear first compensation block between an end point of the first machining block and a start point of a second machining block which was compensated, and by eliminating a predetermined distance from the start point of a third machining block, creates a starting point of this third machining block, and then inserts a second compensation block between the end point of the compensated second machining block and the created starting point of the first machining block.